Just when I think I'm close...

[bronco6778]

After having spent most of the last four weekends rebuilding my suspension, replacing rear brakes, fixing my cooling system leak, and generally cleaning my car, I want to push it off a cliff.

My brake pedal started getting soft last Friday, after having gotten my car inspected and aligned on Thursday and Friday mornings. I assumed the master cylinder was starting to let go and parked it on Friday evening. A prior commitment Saturday kept me from getting any work done, but I did notice a puddle under the rear of the car, in the vicinity of the compensator.

I hoped it was just a loose line or a leaky compensator, so I used it as an excuse to buy a set of flare nut wrenches on the way home from work. Sure enough, there was a drop of brake fluid hanging off one of the hard lines. I asked my dad to pump the brakes so I could confirm where it was and tighten it up, only the fluid was coming from above. Turns out it has a split hard line, and I have no idea what the next step it is, or even where that line goes. The crappy camera phone picture I took is step one. Anybody been through this one before?

P.S. Just to save you the trouble of saying it, I'm aware of how bad the rest of the lines look. I just can't think about it right now. The leaky one is the third one across, the picture is taken from the passenger side of the car.

[danny164l]

Bro Do what I did Spray as many coats of antirust paint an the lines as you can. Remember brake fluid is SUPER corrosive simply because it draws moisture towards it and not away from it. A good layer of paint does the trick.

[Alfisto Steve]

Two of those four lines come from front of car and other go to each rear brake. the ones from front of car go under gas tank.

Winter road salt has got to them it appears.

Slow down take a deep breath and relax it will all work out. Look at the bright side you got car inspected, to bad they didn't see the problem but the good is now you can fix it without having to get it reinspected. Your dad can be the inspector and you guys can fix it right.

Be advised that the lines have different size fittings on ends to prevent hooking them up wrong. You may have to reuse fittings on new generic replacement lines.

If you have to remove lines under tank you will need to jack stand car for safety, remove four bolts holding sub frame and let it hang down on suspension arms, then lower tank (use a board under tank on a jack. You will need to pull front carpet wall in tank and disconnect large vent hose from top of tank but wires and other tubing can stay connected as you can leave tank on jack and board.

[bronco6778]

Thanks Steve. The initial despair has died down, and I'm getting plans into place. Naturally I'm not in love with the fact that I have to do it, but I'll probably go ahead and replace both of the hard lines coming from the front. Should be rolling again in a few weeks.

[bronco6778]

Drove the car up to my friends house today and dug in. I do not recommend it, but I love adventure...

Anyway, we went ahead and pulled the gas tank out, as it was pretty much impossible to get the lines down with it in place. I wish I hadn't put ten gallons in it right before I realized what was wrong. All four of the lines going into the compensator are in bad shape, so all four are getting replaced. I hate doing things twice. The parking brake mechanism on the right rear was frozen, so it's getting a new caliper.

Hopefully we'll button it up next weekend. I'll give a progress report and try to take some pictures.

[Alfisto Steve]

I pulled tank and lines from that old silver parts 164 that Paul had in lot quite awhile back. Tank had super bad gas/fungus and long brake lines rusted, too. but I took lines for fittings and tank just in case my radiator shop can salvage it as I need two tanks. Have lines/fittings soaking in PB blaster in hopes I can get fittings to free up. Those two larger wrench size fittings (to murphy proof the line hook up) pretty unusual since all line diameters the same.

See my post on brake line flare nut fittings.

[bronco6778]

After four new brake lines, two calipers, and a compensator, I think it's done. It definitely isn't leaking fluid anymore. I took advantage of the fuel tank being out to do a couple maintenance related items with the pump and replace a vent line that was split. Hopefully that will cure the fuel smell with a full tank problem. After nearly a month down and the agony of not being able to drive the car after re-doing the suspension, it is great to be back in it. The firmer (working) suspension found a few new rattles in the interior, which I will have to trace, but the car should be good for awhile now.

Next I'm updating the audio system to a modern setup featuring built in iPod and satellite radio controls, plus Bluetooth. But that will be its own thread...

[Alfisto Steve]

Sounds like the plan is coming together at last. Good luck with next project.